Electrical
Poor Performance - Tach Needle Erratic

f the engine misfires or backfires under acceleration, you might also notice the tach needle jumping out of phase with the engine. This would indicate a problem with the spark box triggering the #1-3 cylinders  Read More...
Knowledge base > Electrical > DD-504
Alternator/Rectifier 3-Wire Connector Burned
Article # DD-504
 
 


There are 3 yellow wires coming from the alternator and connect to the rectifier using a plastic male/female connector near the battery. The plastic connector is known to melt due to heat from the wires at the connection. The most common cause for the wires heating is when the battery is not fully charged, not capable of holding a charge, or has been jumped using a running car. Once the connector melts, it allows the 3 wires to short against each other and further burn the connectors and wires. It can also blow the main fuse.

There are a couple ways to correct the problem. Some will solder the wires together. The good thing is soldering is quick. The down side is replacing the rectifier or removing the engine at a later time means you would have to cut it apart. If you choose to solder the connection, be certain to use silver solder and make sure all bare wire is covered and isolated from the frame and other wires with shrink tube.

The recommended repair is to install the Honda OEM repair connector kit. The Honda repair kit includes a new plastic connector fitted with the male and female wire ends with a length of wire attached to each. The replacement connector is spliced into the existing wire harness, and allows you to cut off any burnt or damaged wires. The repair kit also includes solder, shrink tube, and instructions. You can attach any yellow wire to any yellow wire from the two components (alternator and rectifier), they just can't short against each other, or ground to the frame.